Three-Dimensionally Braided Preform for a Composite Connecting Rod: Concept Development and Demonstration

Abstract

The focus of this study was to demonstrate the feasibility of manufacturing near-net-shape (NNS) three-dimensionally braided connecting rod preforms for 4-stroke automobile engines. Based on a design methodology, several design concepts for the NNS manufacturing of connecting rod preforms have been demonstrated. Making use of the concept of geometric hybrid design, the regions of near stress concentration and crack initiation were strategically reinforced. A parallel study was also carried out to assess the feasibility of resin impregnation into the dense 3-D fiber network of connecting rod preforms.By demonstrating the feasibility for NNS manufacturing of the connecting rod preforms, this study has established a foundation for further exploration of large scale manufacturing as well as stimulating more creative use of 3-D braided fibrous structures for the structural reinforcement of automobile components.